Enclosure assembly for enhanced cooling of direct drive unit and related methods

ABSTRACT

Embodiments of an enclosure assembly to enhance cooling of a hydraulic fracturing direct drive unit (DDU) during operation are included. The enclosure assembly may include an enclosure body extending at least partially around an enclosure space to house the DDU for driving a fluid pump. The enclosure assembly may include one or more heat exchanger assemblies connected to the enclosure body for cooling a process fluid associated with one or more of the DDU and the fluid pump, and which may be configured to draw air into the enclosure space from and external environment, toward one or more radiator assemblies to cool the process fluid, and along an airflow path through the enclosure space. One or more outlet fan assemblies may be operative to discharge air from the enclosure space to the external environment to maintain a desired temperature of the enclosure space.

PRIORITY CLAIM

This is a continuation of U.S. Non-Provisional application Ser. No.18/096,927, filed Jan. 13, 2023, titled “ENCLOSURE ASSEMBLY FOR ENHANCEDCOOLING OF DIRECT DRIVE UNIT AND RELATED METHODS,” which is acontinuation of U.S. Non-Provisional application Ser. No. 17/444,485,filed Aug. 5, 2021, titled “ENCLOSURE ASSEMBLY FOR ENHANCED COOLING OFDIRECT DRIVE UNIT AND RELATED METHODS,” now U.S. Pat. No. 11,627,683,issued Apr. 11, 2023, which is a continuation of U.S. Non-Provisionalapplication Ser. No. 17/356,063, filed Jun. 23, 2021, titled “ENCLOSUREASSEMBLY FOR ENHANCED COOLING OF DIRECT DRIVE UNIT AND RELATED METHODS,”now U.S. Pat. No. 11,129,295, issued Sep. 21, 2021, which is adivisional of U.S. Non-Provisional application Ser. No. 17/302,039,filed Apr. 22, 2021, titled “ENCLOSURE ASSEMBLY FOR ENHANCED COOLING OFDIRECT DRIVE UNIT AND RELATED METHODS,” now U.S. Pat. No. 11,109,508,issued Aug. 31, 2021, which claims priority to and the benefit of, under35 U.S.C. § 119(e), U.S. Provisional Application No. 62/705,042, filedJun. 9, 2020, titled “ENCLOSURE ASSEMBLY FOR ENHANCED COOLING OF DIRECTDRIVE UNIT AND RELATED METHODS,” and U.S. Provisional Application No.62/704,981, filed Jun. 5, 2020, titled “ENCLOSURE ASSEMBLY FOR ENHANCEDCOOLING OF DIRECT DRIVE UNIT (DDU) AND RELATED METHODS,” the disclosuresof which are incorporated herein by reference in their entireties.

TECHNICAL FIELD

This disclosure relates to enclosure assemblies and related systems andmethods for providing enhanced cooling of a direct drive unit (DDU),such as a direct drive turbine (DDT) connected to a gearbox for drivinga driveshaft connected to a pump for use in a hydraulic fracturingsystems and methods.

BACKGROUND

During fracturing operations, the equipment onboard fracturing trailersutilizes extensive cooling to facilitate operation throughout thepumping stage. The fracturing pump may have, for example, up to 5%energy loss of energy through heat rejection during operation. Such heatrejection may enter bearings, connecting rods, the casing, clamps andother highly temperature sensitive components in the pumps power end.These components are typically kept lubricated and cooled using lube oilthat is pumped continuously through circuits into the pump ensuring thatthe lube oil is cascaded around the crank case of the fluid pump.

Heat rejection from the pump is still absorbed into the oil, however,and this oil is cooled through a lubrication circuit to ensure that theoil remains at a manageable temperature set out by regulation and/orpump original equipment manufacturers (OEMs). The cooling of oil may beachieved by diverting the oil to a heat exchanger (for example, a fandriven heat exchanger, tube and shell heat exchanger, or other heatexchanger as will be understood by those skilled in the art.) that is besized and configured to be able to remove enough heat from the fluidthat will allow the oil to enter the crank case again and absorb moreheat rejection.

This cooling cycle may occur constantly onboard fracturing trailers withthe operations of the heat exchangers at times being hydraulically orelectrically driven. The need for higher power rated fracturing pumps,for example, 5000HP or 7000HP rated fracturing pumps, may require largercooling packages to be able to manage the heat rejection. Accordingly,more heat rejection may directly correlate to the physical footprint ofthe cooling systems.

SUMMARY OF THE DISCLOSURE

In view of the foregoing, there is an ongoing need for an enclosureassembly and related systems and methods that are more suitable forcooling the DDU of a pumping system, as well as for high-pressure andhigh-power operations.

Accordingly, it may be seen that a need exists for managing the locationof cooling systems to minimize physical footprint, for managingassociated power resources efficiently, and for providing effectivecooling for fracturing pumps and DDUs. The present disclosure addressesthese and other related and unrelated problems in the art.

One exemplary embodiment of the disclosure includes an enclosureassembly to enhance cooling of a hydraulic fracturing direct drive unit(DDU) during operation. An enclosure body may be provided extending atleast partially around an enclosure space to house the DDU, which mayinclude a turbine engine that is mechanically connected to a gearbox fordriving a driveshaft connected to the gearbox in order to drive a fluidpump. The enclosure assembly may include one or more heat exchangerassemblies connected to the enclosure body for cooling a process fluidassociated with one or more of the DDU and the fluid pump, for example,a lubrication or other lubrication medium, and/or a hydraulic/workingfluid that is heated during operation. The one or more heat exchangerassemblies may include one or more intake fan assemblies positioned influid communication with an external environment surrounding theenclosure body, and one or more intake fan motors may be operativelyconnected to the one or more intake fan assemblies. Thus, when the oneor more intake fan motors is activated, the one or more intake fanassemblies may draw air into the enclosure space from the externalenvironment at the one or more intake fan assemblies and along anairflow path through the enclosure space. One or more radiatorassemblies may further be included in the one or more heat exchangerassemblies for receiving the process fluid, and positioned adjacent theone or more intake fan assemblies in the airflow path through theenclosure space to cool the process fluid with air from the externalenvironment as it flows toward the radiator assembly.

In addition, the enclosure assembly may include one or more outlet fanassemblies positioned in fluid communication with the externalenvironment. Accordingly, to maintain a desired temperature of theenclosure space, the one or more outlet fan assemblies may beoperatively connected to one or more outlet fan motors to discharge airfrom the enclosure space to the external environment when the one ormore outlet fan motors is activated such that airflow heated by thecooling of the process fluid may be ventilated from the enclosureassembly. The enclosure assembly may also include one or moretemperature sensors to detect a temperature of the enclosure space and,further, one or more controllers in electrical communication with theone or more temperature sensors. The one or more controllers may beoperatively connected to one or more of the one or more intake fanmotors and the one or more outlet fan motors. In this regard, the one ormore controllers may activate the respective one or more intake fanmotors and the one or more outlet fan motors to rotate the respectiveone or more intake fan assemblies and the one or more outlet fanassemblies responsive to a predetermined temperature signal from the oneor more temperature sensors to discharge heated air from and maintain adesired temperature of the enclosure space.

Another exemplary embodiment of the disclosure includes a fluid pumpingsystem for high-pressure, high-power hydraulic fracturing operations.The system may include a direct drive unit (DDU) having a turbine enginemechanically connected to a gearbox for driving a driveshaft, and afluid pump operatively connected to the DDU by the driveshaft fordriving the fluid pump. Accordingly, one or more of the DDU and thefluid pump may generate and heat process fluid during operation, whichmay include lubrication oil or another lubrication medium, and/or ahydraulic or other working fluid. The system may include an enclosureassembly having an enclosure body extending around an enclosure space tohouse the DDU, and one or more or more heat exchanger assembliesconnected to the enclosure body for cooling process fluid associatedwith one or more of the DDU and the fluid pump. The one or more heatexchanger assemblies of the system may include one or more intake fanassemblies positioned in fluid communication with an externalenvironment surrounding the enclosure body, and one or more intake fanmotors may be operatively connected to the one or more intake fanassemblies. When the one or more intake fan motors is activated, the oneor more intake fan assemblies may draw air into the enclosure space fromthe external environment at the one or more intake fan assemblies andalong an airflow path through the enclosure space. One or more radiatorassemblies may be included in the one or more heat exchanger assembliesfor receiving the process fluid, and may be positioned adjacent the oneor more intake fan assemblies in the airflow path through the enclosurespace to cool the process fluid with the air drawn in from the externalenvironment as it flows through the radiator assembly.

The system's enclosure assembly may also include one or more outlet fanassemblies positioned in fluid communication with the externalenvironment. In order to maintain a desired temperature of the enclosurespace, the one or more outlet fan assemblies may be operativelyconnected to one or more outlet fan motors to discharge air from theenclosure space to the external environment when the one or more outletfan motors is activated so that airflow in the enclosure space that hasbeen heated from the cooling of the process fluid may be ventilated fromthe enclosure assembly. The enclosure assembly of the system may alsoinclude one or more temperature sensors to detect a temperature of theenclosure space and, further, one or more controllers in electricalcommunication with the one or more temperature sensors. The one or morecontrollers may be operatively connected to one or more of the one ormore intake fan motors and the one or more outlet fan motors. In thisregard, the one or more controllers may activate the respective one ormore intake fan motors and the one or more outlet fan motors to rotatethe respective one or more intake fan assemblies and the one or moreoutlet fan assemblies responsive to a predetermined temperature signalfrom the one or more temperature sensors to discharge heated air fromand maintain a desired temperature of the enclosure space

Still another exemplary embodiment of the disclosure includes a methodof enhancing cooling during operation of a hydraulic fracturing directdrive unit (DDU) having a turbine engine mechanically connected to agearbox. The method may include operating the DDU to drive a driveshaftoperatively connected to a fluid pump such that one or more of theturbine engines and the fluid pump generate and heat process fluid, forexample, a lubrication or other lubrication medium, and/or ahydraulic/working fluid. The method may include detecting a temperaturein an enclosure space of an enclosure assembly housing the DDU with oneor more temperature sensors, and, further, controlling one or moreintake fan assemblies of one or more heat exchanger assemblies in theenclosure space to draw air from an external environment into an airflowthrough the enclosure space based upon a temperature signal detected bythe one or more temperature sensors. In this regard, the method mayinclude cooling the process fluid by directing airflow from the one ormore intake fan assemblies toward one or more radiator assemblies of theone or more heat exchangers carrying the process fluid. The method mayfurther include controlling one or more outlet fan assemblies todischarge airflow heated by the cooling of the process fluid to theexternal environment to maintain a desired temperature in the enclosurespace.

Those skilled in the art will appreciate the benefits of variousadditional embodiments reading the following detailed description of theembodiments with reference to the below-listed drawing figures. It iswithin the scope of the present disclosure that the above-discussedembodiments be provided both individually and in various combinations.

BRIEF DESCRIPTION OF THE DRAWINGS

According to common practice, the various features of the drawingsdiscussed below are not necessarily drawn to scale. Dimensions ofvarious features and elements in the drawings may be expanded or reducedto more clearly illustrate the embodiments of the disclosure.

FIG. 1A is a schematic diagram of a pumping unit according to anembodiment of the disclosure.

FIG. 1B is a schematic diagram of a layout of a fluid pumping systemaccording to an embodiment of the disclosure.

FIG. 2 is a perspective view of an enclosure assembly according to anembodiment of the disclosure.

FIG. 3 is a schematic sectional view of an enclosure body according toan embodiment of the disclosure.

FIG. 4 is a schematic sectional view of an enclosure assembly accordingto an embodiment of the disclosure.

FIG. 5 is a schematic diagram of a heat exchanger assembly according toan embodiment of the disclosure.

FIG. 6 is a front view of a heat exchanger assembly according to anembodiment of the disclosure.

FIG. 7 is a side view of a heat exchanger assembly according to anembodiment of the disclosure.

FIG. 8 is a plan sectional view of an enclosure assembly according to anembodiment of the disclosure.

FIG. 9 is a side sectional view of an enclosure assembly according to anembodiment of the disclosure.

FIG. 10 is a schematic diagram of a hydraulic circuit according to anembodiment of the disclosure.

FIG. 11 is a schematic diagram of a control circuit according to anembodiment of the disclosure.

Corresponding parts are designated by corresponding reference numbersthroughout the drawings.

DETAILED DESCRIPTION

The embodiments of the present disclosure are directed to enclosureassemblies to enhance cooling of a hydraulic fracturing direct driveunit (DDU) during operation. The embodiments of the present disclosuremay be directed to such enclosure assemblies for enhanced cooling ofDDUs associated with high-pressure, high-power hydraulic fracturingoperations.

FIG. 1A illustrates a schematic view of a pumping unit 111 for use in ahigh-pressure, high power, fluid pumping system 113 (FIG. 1B) for use inhydraulic fracturing operations according to an embodiment of thedisclosure. FIG. 1B shows a typical pad layout of the pumping units 111(indicated as FP1, FP2, FP3, FP4, FP5, FP6, FP7, FP8) with the pumpingunits all operatively connected to a manifold M that is operativelyconnected to a wellhead W.

By way of an example, the system 113 is a hydraulic fracturingapplication that may be sized to achieve a maximum rated horsepower of24,000 HP for the pumping system 113, including a quantity of eight (8)3000 horsepower (HP) pumping units 111 that may be used in oneembodiment of the disclosure. It will be understood that the fluidpumping system 113 may include associated service equipment such ashoses, connections, and assemblies, among other devices and tools. Asshown in FIG. 1A, each of the pumping units 111 are mounted on a trailer115 for transport and positioning at the jobsite. Each pumping unit 111includes an enclosure assembly 121 that houses a direct drive unit (DDU)123 including a gas turbine engine 125 operatively connected to agearbox 127 or other mechanical transmission.

The pumping unit 111 has a driveshaft 131 operatively connected to thegearbox 127. The pumping unit 111 includes a high-pressure, high-power,reciprocating positive displacement pump 133 that is operativelyconnected to the DDU 123 via the driveshaft 131. In one embodiment, thepumping unit 111 is mounted on the trailer 115 adjacent the DDU 123.

The trailer 115 includes other associated components such as a turbineexhaust duct 135 operatively connected to the gas turbine engine 125,air intake duct 137 operatively connected to the gas turbine, and otherassociated equipment hoses, connections, or other components as will beunderstood by those skilled in the art to facilitate operation of thefluid pumping unit 111.

In the illustrated embodiment, the gas turbine engine 125 may be aVericor Model TF50F bi-fuel turbine; however, the DDU 123 may includeother gas turbines or suitable drive units, systems, and/or mechanismssuitable for use as a hydraulic fracturing pump drive without departingfrom the disclosure. In one embodiment, the fluid pumping system 113 mayinclude a turbine engine that uses diesel or other fuel as a powersource. The gas turbine engine 125 is cantilever mounted to the gearbox127, with the gearbox 127 supported by the floor of the enclosureassembly 121.

It should also be noted that, while the disclosure primarily describesthe systems and mechanisms for use with DDUs 123 to operate fracturingpumping units 111, the disclosed systems and mechanisms may also bedirected to other equipment within the well stimulation industry suchas, for example, blenders, cementing units, power generators and relatedequipment, without departing from the scope of the disclosure.

FIGS. 2 and 4 illustrate an enclosure assembly 121 that houses the DDU123 according to an exemplary embodiment of the disclosure. As shown,the enclosure assembly 121 includes an enclosure body 165 that mayextend at least partially around an enclosure space 122 to house one ormore portion of the DDU 123 therein. The enclosure space 122 may also besized and configured to accommodate other DDU/engine equipment, forexample, a driveshaft interface, fuel trains, an exhaust system flangedconnection, a fire suppression system, bulkheads, exhaust ducting,engine air intake ducting, hydraulic/pneumatic bulkhead hoses,inspection doors/hatches, or other components and equipment as will beunderstood by those skilled in the art.

In one embodiment, the enclosure body 165 may be a generally box-like orcuboid arrangement of walls, including a first side wall 167, a secondside wall 169 opposite the first side wall 167, and an opposing frontwall 171 and rear wall 173 each extending from the first side wall 167to the second side wall 169. The enclosure body 165 may also include aroof/top wall 166 (FIG. 4 ) and a floor/bottom wall 168. In oneembodiment, the floor 168 may be formed of a solid base steel materialmounted on a skid structure.

Referring additionally to FIG. 3 , one or more of the walls of theenclosure body 165 may be provided with sound-attenuating, e.g.,vibration-dampening, properties to minimize the transmission of soundfrom one or more operations of the DDU 123, e.g., running of the turbineengine 125 and/or the gearbox 127, from the enclosure space 122 to anexternal environment surrounding the enclosure body 165. In this regard,the walls of the enclosure body 165 may have a configuration in whichmultiple layers are arranged to provide sound attenuation. Othersound-attenuating features may be incorporated into the construction ofthe enclosure assembly 121. For example, the gearbox 127 may be providedwith shock-absorbing feet or mounts that minimize the transmission ofvibrations to the enclosure body 165.

In one embodiment, the walls of the enclosure body 165 may include anouter metallic layer 171, a foam or other polymeric layer 173 and acomposite layer 175, and in inner or liner metallic layer 177, with thefoam layer 173 and the composite layer 175 positioned between themetallic layers 171, 177.

In one embodiment, the walls 167, 169, 171, 173 of the enclosure body165 may be formed from approximately 12″×12″ panels with an overallthickness of about 4.5″ to about 5.25″ that may clip, snap, or otherwiseconnect together in a generally modular arrangement, and the outermetallic layer 171 may be, for example, a 22 ga perforated aluminumsheet, the foam layer 173 may be, for example, a 1″ foam layer, thecomposite layer 175 may be, for example, a 3″-4″ layer of mineral wool,and the inner metallic layer 177 may be, for example, perforated 22 gaaluminum. The roof 166 of the enclosure body 165 may have a similararrangement, with an overall thickness of, for example, about 2″ andhaving the foam layer 173 at a thickness of about, for example, 1.5″.The enclosure body 165 may have a different arrangement withoutdeparting from the disclosure.

Still referring to FIG. 2 , a plurality of doors may be movablyconnected/attached to the enclosure body 165, e.g., to provide access tothe enclosure space 122 for inspections, maintenance, or otheroperations as will be understood by those skilled in the art. A pair ofdoors 179 may be hingably connected/attached to the first side wall 167of the enclosure body 165 to provide access to the enclosure space 122through openings formed in the first side wall 167 upon movement of thedoors 179.

A door 181 may also be movably connected to the second side wall 169 ofthe enclosure body 165 to provide access to the enclosure space 122along the second side wall 169. In one embodiment, the door 181 may beslidably connected/attached to the second side wall 169 on rails,tracks, or other guides as will be understood by those skilled in theart, such that slidable movement of the door 181 exposes an opening inthe second side wall 169 through which an operator may access theenclosure space 122. In one embodiment, the door 181 may have one ormore foldable or otherwise reconfigurable portions.

With additional reference to FIG. 4 , a generally horizontal partition183 may extend in general parallel relation with the roof 166 and thefloor 168 of the enclosure body 165 so as to provide an uppercompartment 185 and a lower compartment 187 of the enclosure space 122.In one embodiment, the upper compartment 185 may include an air intakeassembly that may include an arrangement of ducts, fans, ports,filtration assemblies, blowers, compressors, cooling coils, or othercomponents as will be understood by those skilled in the art, to feedfiltered air into the turbine engine 123 positioned in the lowercompartment 187.

In view of the foregoing, the enclosure assembly 121 may be providedwith a generally weatherproof or weather-resistant configuration that issufficiently robust for use in hydraulic fracturing applications, andwhich additionally provides sound attenuation properties for enclosedand associated equipment. For example, the enclosure assembly 121 mayprovide sufficient sound attenuation emanating from one or moreincorporated heat exchanger assemblies, as described further herein.

During various operations of the pumping unit 133, e.g., startup andshutdown procedures, idling, maintenance cycles, active driving of thepumping unit 133, or other operations as will be understood by thoseskilled in the art, heat may be generated in one or more portions of thepumping unit 133, for example, via frictional engagement of componentsof the pumping unit 133 such as pistons, bores, or other components aswill be understood by those skilled in the art. In this regard, thepumping unit 133 may employ a fluid heat transfer medium, e.g., anatural or synthetic lubrication oil, to absorb heat from the pumpingunit 133 via fluid convection to reduce heat in one or more portions ofthe DDU 123.

Similarly, during various operations of the DDU 123, heat may begenerated by one or more portions of the turbine engine 125 and thegearbox 127. The DDU 123 may thus also employ a fluid heat transfermedium to absorb heat from the DDU 123 via fluid convection to reduceheat in one or more portions of the DDU 123.

Further, various hydraulic components of the fluid pumping system 113,e.g., actuators, motors, pumps, blowers, coolers, filters, or otherhydraulic components as will be understood by those skilled in the art,that receive pressurized hydraulic fluid or working fluid therethroughmay cause such hydraulic fluid/working fluid to increase in temperatureduring the course of such operation.

The aforementioned fluid heat transfer media, hydraulic fluids/workingfluids, and other thermally conductive fluids associated with the fluidpumping system 113 may be collectively referred to as process fluidsassociated with the respective components of the fluid pumping system113 herein.

In this regard, the fluid pumping system 113 may include one or moreheat exchanger assemblies for cooling/reducing heat in theaforementioned process fluids. Turning to FIG. 5 , a heat exchangerassembly 189A according to an exemplary embodiment of the disclosure isschematically illustrated. In the illustrated embodiment, the heatexchanger assembly 189A may be connected to, e.g., attached, mounted, orotherwise supported by, the enclosure body 165. While the heat exchangerassembly 189A is illustrated as being positioned in the enclosure space122, it will be understood that the heat exchanger assembly 189A may beconnected to the enclosure body 165 and at least partially positionedoutside thereof without departing from the disclosure.

Still referring to FIG. 5 , the heat exchanger assembly 189A may includeone or more intake fan assemblies 193, one or more intake fan motors 195operatively connected to the intake fan assembly 193, and one or moreradiator assemblies 197 positioned adjacent the intake fan assembly 193.The heat exchanger assembly 189A may be positioned in alignment with acutout or opening in the enclosure body 122, e.g., so that the heatexchanger assembly 189A may be in at least partial fluid communicationwith an external environment E surrounding the enclosure assembly 121.In one embodiment, such cutout or opening may be at least partiallycovered with a mounting plate 194 which may be connected to the heatexchanger assembly 189A.

A sealing member 198, for example, a gasket or other polymeric member,may be positioned between the heat exchanger assembly 189A and theenclosure body 165, for example, to inhibit the migration or leakage offluids between the heat exchanger assembly 189A and the enclosure body165.

The one or more intake fan assemblies 193 may include one or more fans205 (FIG. 6 ) rotatably connected to the intake fan motor 195 such that,upon receiving a driving signal or other modality of actuation, theintake fan motor 195 rotates the one or more fans 205 to rotate andcirculate air through the enclosure space 122. Such rotatable connectionbetween the intake fan motor 195 and the fan 205 may be a driveshaft,coupling, or other mechanical transmission. The fan 205 may have aplurality of blades/arms for forcing/urging air into an airflow. In thisregard, the fan 205 may be provided with blades/arms having a length,pitch, shape, or other features as will be understood by those skilledin the art, configured to influence airflow in a preselected direction.

As shown, the one or more radiator assemblies 197 is positioned adjacentthe intake fan assembly 193. In one embodiment, the radiator assembly197 may be configured as a tube-and-shell heat exchanger, in which oneor more conduits (e.g., tubes, ducts, hoses, fluid lines, or otherconduits as will be understood by those skilled in the art) extend alongbulkhead fittings on the enclosure body 122 and through an interior of ahousing shell 207 to route the process fluid over a sufficient surfacearea to effect cooling of the process fluid.

The conduits extending through the housing shell 207 may carry processfluid in the form of a fluid heat exchange medium, hydraulicfluid/working fluid, or other fluid. As described further herein, theradiator assembly 197 may be positioned in an airflow path at leastpartially provided by the intake fan assembly 193 to remove heat fromthe process fluid running through the conduits. In one embodiment, theradiator assembly 197 may be covered by/positioned adjacent one or morelayers of mesh or otherwise porous material.

Referring to FIGS. 6 and 7 , the enclosure assembly 121 may include theheat exchanger assembly 189A (broadly, “low-pressure heat exchangerassembly 189A) for cooling process fluid received from a low-pressureportion of the fluid pump 133, and the enclosure assembly 121 mayfurther include a high-pressure heat exchanger assembly 189B for coolingprocess fluid received from a high-pressure portion of the fluid pump133. The heat exchanger assembly 189B may be similarly configured to theheat exchanger assembly 189A, though the heat exchanger assemblies 189A,189B may have one or more differences without departing from thedisclosure.

As also shown, the heat exchanger assemblies 189A, 189B are supported ona mounting frame 191 with a generally rigid body having outer framemembers 199, 200 intersecting at respective joints/plates 201 that maybe secured with fasteners such as bolts, screws, rivets, pins, or otherfasteners as will be understood by those skilled in the art. As alsoshown, the mounting frame 191 is provided with one or more flanges orsecuring tabs 203 extending from one or more of the frame members 199,200 and that are configured for engagement with the enclosure body 165.In this regard, the securing tabs 203 may have, for example, a generallyflat or planar profile and/or may be provided with an opening forreceiving a fastener therethrough. In one embodiment, the securing tabs203 may be integrally formed with one or more of the frame members 199,200.

The heat exchanger assemblies 189A, 189B may both be connected to themounting frame 191 in a vertically stacked arrangement, as shown, thougheach heat exchanger assembly 189A, 189B may be connected to theenclosure body 165 on separate mounting frames without departing fromthe disclosure. In one embodiment, the mounting frame 191 may be about0.25″ thick, and may be provided with a tolerance of about 0.1″ to about0.2″ beyond the boundaries of the heat exchanger assemblies 189A, 189B.

In one embodiment, the mounting frame 191 may be connected to a modularpanel of the side wall 167 that is sized and configured to an arealarger than that of the heat exchanger assemblies 189A, 189B. In oneembodiment, such modular panel may be provided with a tolerance of about0.35″ to about 0.45″ beyond the heat exchanger assemblies 189A, 189B.

In one embodiment, and as shown in FIG. 2 , the enclosure assembly 121may include additional or alternative heat exchangers, for example, aheat exchanger 189C for cooling process fluid associated with theturbine engine 125, a heat exchanger 189D for cooling process fluidassociated with the gearbox 127, and a heat exchanger 189E for coolingprocess fluid associated with one or more hydraulic components of thefluid pumping system 113 (e.g., auxiliary/ancillary actuators, pumps,motors, or other hydraulic components as will be understood by thoseskilled in the art). It will be understood that each of the heatexchanger assemblies 189A, 189B, 189C, 189D, 189E may besized/scaled/configured according to the process fluids upon which theyare operative to cool.

As described herein, the heat exchanger assemblies 189C, 189D, 189E mayhave a configuration that is substantially similar to that of the heatexchanger assemblies 189A and 189B, though one or more of the heatexchanger assemblies 189A, 189B, 189C, 189D, 189E may have a differentconfiguration without departing from the disclosure. By way of example,two or more of the one or more of the heat exchanger assemblies 189A,189B, 189C, 189D, 189E may share a common mounting frame, housing shell,intake fan assembly, or other component as will be understood by thoseskilled in the art.

As shown in FIG. 2 , the heat exchanger assemblies 189A, 189B, 189C,189D, 189E are connected to the enclosure body 165 and positioned influid communication with the external environment E such that when therespective intake fan assemblies 193 are driven by the respective intakefan motors 195, the intake fan assemblies 193 are operative to draw airin from the external environment E toward the respective radiatorassemblies 197 to remove heat/cool the process fluids flowingtherethrough, and so that they may return to respective portions of thefluid pumping system for continued lubrication/cooling of components ofthe fluid pumping system 113.

The aforementioned action of the intake fan assemblies 193 causes airfrom the external environment E to absorb heat from the radiatorassemblies 197 as it passes thereby/therethrough and further into theenclosure space 122. In this regard, operation of one or more of theheat exchanger assemblies 189A, 189B, 189C, 189D, 189E may cause anambient temperature in the enclosure space 122 of the enclosure assembly121 to increase.

With additional reference to FIGS. 8 and 9 , one or more outlet/suctionfan assemblies 209 may also be connected to the enclosure body 165. Theone or more outlet fan assemblies 209 may have a similar configurationto the aforementioned intake fan assemblies 193, in that they mayinclude one or more outlet fans, e.g., a fan 205, in operativecommunication with one or more respective motors, e.g., an outlet fanmotor 196, such that upon receiving a driving signal or actuation force,the outlet fan motor 196 may drive the fan 205 to rotate. In oneembodiment, the outlet fan assembly 209 may include a pair of fans 205driven by one or more outlet fan motors 196. It will be understood thatthe one or more inlet fan assemblies 193 and the one or more outlet fanassemblies 209 may be driven by the same motor or combination of motors.Although the one or more outlet fan assemblies 209 has been describedherein separately from the heat exchanger assemblies 189A, 189B, 189C,189D, 189E, it will be understood that one or more of the heat exchangerassemblies 189A, 189B, 189C, 189D, 189E may include the one or moreoutlet fan assemblies 209 without departing from the disclosure.

In one embodiment, one or more of the heat exchanger assemblies 189A,189B, 189C, 189D, 189E may be attached to the first side wall 167 of theenclosure body 165, and the outlet fan assembly 209 may be attached tothe second side wall 169 of the enclosure body 165. It will beunderstood that the heat exchanger assemblies 189A, 189B, 189C, 189D,189E and the outlet fan assembly 209 may be attached to the enclosurebody 165 in a different arrangement without departing from thedisclosure.

In this regard, upon receipt of an actuation force or driving signal,the one or more outlet fan motors 196 associated with the outlet fanassembly 209 may rotate the fan 205 to discharge air from the enclosurespace 122 to the external environment E. Accordingly, the arrangement ofthe heat exchanger assemblies 189A, 189B, 189C, 189D, 189E and theoutlet fan assembly 209 is operative to draw atmospheric/cool air infrom the external environment E at the intake fan assembly 193, directairflow toward the radiator assembly 197 to cool the process fluidsflowing therethrough, and, further, to ventilate the enclosure assembly121 by directing an airflow path A from the intake fan assembly 193 tothe outlet fan assembly 209 and discharging the air from the enclosurespace 122/airflow path A that has been heated from cooling the radiatorassembly 197 to the external environment E at the outlet fan assembly209.

Still referring to FIGS. 8 and 9 , in one embodiment, one or more of theheat exchanger assemblies 189A, 189B, 189C, 189D, 189E, in cooperationwith the one or more outlet fan assemblies 209, is configured to replacea volume of air in the enclosure space 122 at an interval of about 30seconds. It will be understood that the heat exchanger assemblies may beconfigured to replace the same or a different volume of air at adifferent time interval without departing from the disclosure.

Accordingly, the enclosure assembly 121 may be provided with enhancedcooling capabilities for managing excess heat generated by one or moreof the DDU 123, the fluid pump 113, and various hydraulic componentsassociated with the fluid pumping system 113. As described above, one ormore of the heat exchanger assemblies 189A, 189B, 189C, 189D, 189E isoperative to cool process fluid associated with one or more of the DDU123, the fluid pump 113, and various hydraulic components associatedwith the fluid pumping system 113. Further, the intake fan assemblies193 of the heat exchanger assemblies 189A, 189B, 189C, 189D, 189E directthe airflow path A through the enclosure space 122 such that, incooperation with the outlet fan assembly 209, the air in the enclosurespace 122 may be discharged to the external environment E to provideventilation in the enclosure space 122. Such ventilation may, forexample, maintain a desired temperature of the enclosure space 122,e.g., to further enhance a temperature differential between the airflowpath A and the process fluid in the heat exchanger assemblies 189A,189B, 189C, 189D, 189E.

As described herein, one or more of the motors 195, 196 may be hydraulicmotors, e.g., such that a pressurized working fluid/hydraulic fluidflows therethrough to actuate the motors 195, 196.

With additional reference to FIG. 10 , a schematic diagram is providedto show a hydraulic circuit that may be used to drive one or more of thefans 205 of the respective intake fan assemblies 193. As shown, eachintake fan motor 195 includes an inlet port 211 in fluid communicationwith a hydraulic pump 213 to receive pressurized fluid from thehydraulic pump 213 to actuate the respective intake fan motor 195. Theintake fan motors 195 are also in fluid communication with a return portor outlet port 215 in fluid communication with the hydraulic pump 213 toreturn hydraulic fluid/working fluid to the respective hydraulic pump213 after it has passed through/actuated the respective intake fan motor195. Each intake fan motor 195 may also include a drain port 217 influid communication therewith, for example, to provide drainage ofoverflow/excess hydraulic fluid/working fluid, to provide a leakage pathor pressure release, or other fluid release as will be understood bythose skilled in the art. It will be understood that the one or moreoutlet fan motors 196 may be arranged/controlled in a manner similar tothat described above with regard to the inlet fan motors 195.

It will be understood that the hydraulic pump 213 may be in fluidcommunication with the respective fluid pump 133, the turbine engine125, the gearbox 127, and one or more hydraulic components of the fluidpumping system 113 to receive and return process fluid thereto, forexample, through an arrangement of fluid lines, manifolds, valves, orother fluid conduit as will be understood by those skilled in the art.In one embodiment, each of the fluid pump 133, the turbine engine 125,the gearbox 127, and one or more hydraulic components of the fluidpumping system 113 may be associated with a separate hydraulic pump 213,or a combination of hydraulic pumps 213. In one embodiment, the motors195 associated with the respective low-pressure portion of the fluidpump 133 and the high-pressure portion of the fluid pump 133 may shareone or more common fluid lines.

Each intake fan motor 195 may have an associated solenoid 219 thatincludes one or more fluid valves to control the flow of hydraulicfluid/working fluid thereto and therefrom. For example, upon receipt ofa predetermined electrical signal, each solenoid 219 may actuate, e.g.,open or dilate, to permit the flow of hydraulic fluid/working fluid fromthe hydraulic pump 213 to the respective inlet port 211 and to permitthe flow of hydraulic fluid/working fluid from the respective outletportion 215 to the hydraulic pump 213. Similarly, the solenoid 219 mayclose, e.g., restrict or block, the flow of hydraulic fluid/workingfluid therethrough upon receipt of a predetermined electrical signal,e.g., a closure signal.

While the intake fan motors 195 described herein have been described ashydraulic motors driven by pressurized hydraulic/working fluid, it willbe understood that one or more of the motors 195 (or the motors 196) maybe an electric motor driven by a received electrical actuation/drivingsignal. In one embodiment, one or more of the motors 195, 196 may be anelectric motor powered from 3-phase electrical power provided by anonboard generator system capable of a voltage output of 480V.

Turning to FIG. 11 , a schematic diagram of a control system that may beused to control the inlet fan motors 195 is illustrated. As shown, eachsolenoid 219 may be electrically connected to a controller 221, e.g., aprogrammable logic controller (PLC), an off-highway multi-controller, aprocessor-implemented controller, or other control feature as will beunderstood by those skilled in the art. In this regard, the controller221 may be operable to actuate the solenoids 219, e.g., to selectivelyopen and close the valves of the solenoid 219 to permit/restrict theflow of hydraulic fluid/working fluid through the respective inlet fanmotors 195. It will be understood that the one or more outlet fan motors196 may be controlled in a manner similar to that described above withregard to the inlet fan motors 195.

In this regard, the controller 221 may be configured to transmit adriving or actuation signal to the respective solenoids 219 upon receiptof a predetermined electrical signal from a thermal/temperature sensor223 that may be in proximity to the process fluid associated with therespective turbine engine 125, gearbox 127, low-pressure portion of thepump 133, the high-pressure portion of the pump 133, and one or morehydraulic components of the fluid pumping system 113. In this regard,one or more temperature sensors 223 may be connected to the enclosureassembly 121 or components thereof. In one embodiment, the sensors 223may be disposed along a fluid line between the outlet port/returnportion 215 of the respective motor 195 and the hydraulic pump 213and/or a respective reservoir for the process fluid carriedtherethrough.

In one embodiment, the sensors 223 may be digital thermometers oranother electronic sensor that may receive/absorb heat from theassociated respective turbine engine 125, gearbox 127, low-pressureportion of the pump 133, the high-pressure portion of the pump 133, andone or more hydraulic components of the fluid pumping system 113, andtransmit a corresponding electrical signal to the controller 221. If therespective electrical signal corresponds to a temperature that is at orabove a predetermined value or threshold, for example, set by regulationor OEMs, the controller 221 may signal the respective solenoid 219 toopen the respective valves.

It will be understood that such actuation of the solenoids 219 may beperformed at a constant or predetermined time interval, on-demand, e.g.,if and when a predetermined signal is received from the sensors 223,and/or may be performed proportionally to the temperature of theenclosure space 122, e.g., so that determining and monitoringgreater/lesser temperatures in the enclosure space 122, the controller221 will proportionally increase/decrease the flow rate ofhydraulic/working fluid flowing through the respective intake fan motors195, and consequently, the speed of the respective associated fans 205.

In one embodiment, one or more of the sensors 223 may include an analogdevice configured to receive/absorb heat and product a correspondinganalog electrical signal without any intermediate processing steps, forexample, as in a thermocouple, resistance temperature detector (RTD), ortemperature switch. Such analog electrical signal may be a raw valuedetermined by the controller 221 or other processor to correspond to atemperature of the enclosure space 122.

While the hydraulic circuit and control of the respective fans 205 hasbeen described above with regard to the heat exchanger assemblies 189A,189B, 189C, 189D, 189E, it will be understood that the fans 205 of theoutlet fan assembly 209 may be driven and controlled in the same or asimilar manner.

Still other embodiments of the disclosure, as shown in FIGS. 1-11 , alsoinclude methods of enhancing cooling during operation of a hydraulicfracturing direct drive unit (DDU) having a turbine engine mechanicallyconnected to a gearbox. An embodiment of a method may include operatingthe DDU to drive a driveshaft operatively connected to a fluid pump suchthat one or more of the turbine engine and the fluid pump generates andheats process fluid, for example, a lubrication or other lubricationmedium, and/or a hydraulic/working fluid. The method may includedetecting a temperature in an enclosure space of an enclosure assemblyhousing the DDU with one or more temperature sensors, and, further,controlling one or more intake fan assemblies of one or more heatexchanger assemblies in the enclosure space to draw air from an externalenvironment into an airflow through the enclosure space based upon atemperature signal detected by the one or more temperature sensors. Inthis regard, the method may include cooling the process fluid bydirecting airflow from the one or more intake fan assemblies toward oneor more radiator assemblies of the one or more heat exchangers carryingthe process fluid. The method may further include controlling one ormore outlet fan assemblies to discharge airflow heated by the cooling ofthe process fluid to the external environment to maintain a desiredtemperature in the enclosure space.

In view of the foregoing, the disclosed embodiments of enclosureassemblies for DDUs may provide for enhanced cooling by theconfiguration and arrangement of one or more heat exchangers that coolone or more process fluids associated with the DDU and/or an associatedfluid pumping system while also providing ventilation and cooling of anenclosure space within the enclosure assembly. In addition to theenhanced cooling of the DDU provided by such an arrangement, thefootprint of the enclosure assembly may be minimized and the managementof associated power systems may be streamlined.

This is a continuation of U.S. Non-Provisional application Ser. No.18/096,927, filed Jan. 13, 2023, titled “ENCLOSURE ASSEMBLY FOR ENHANCEDCOOLING OF DIRECT DRIVE UNIT AND RELATED METHODS,” which is acontinuation of U.S. Non-Provisional application Ser. No. 17/444,485,filed Aug. 5, 2021, titled “ENCLOSURE ASSEMBLY FOR ENHANCED COOLING OFDIRECT DRIVE UNIT AND RELATED METHODS,” now U.S. Pat. No. 11,627,683,issued Apr. 11, 2023, which is a continuation of U.S. Non-Provisionalapplication Ser. No. 17/356,063, filed Jun. 23, 2021, titled “ENCLOSUREASSEMBLY FOR ENHANCED COOLING OF DIRECT DRIVE UNIT AND RELATED METHODS,”now U.S. Pat. No. 11,129,295, issued Sep. 21, 2021, which is adivisional of U.S. Non-Provisional application Ser. No. 17/302,039,filed Apr. 22, 2021, titled “ENCLOSURE ASSEMBLY FOR ENHANCED COOLING OFDIRECT DRIVE UNIT AND RELATED METHODS,” now U.S. Pat. No. 11,109,508,issued Aug. 31, 2021, which claims priority to and the benefit of, under35 U.S.C. § 119(e), U.S. Provisional Application No. 62/705,042, filedJun. 9, 2020, titled “ENCLOSURE ASSEMBLY FOR ENHANCED COOLING OF DIRECTDRIVE UNIT AND RELATED METHODS,” and U.S. Provisional Application No.62/704,981, filed Jun. 5, 2020, titled “ENCLOSURE ASSEMBLY FOR ENHANCEDCOOLING OF DIRECT DRIVE UNIT (DDU) AND RELATED METHODS,” the disclosuresof which are incorporated herein by reference in their entireties.

The foregoing description of the disclosure illustrates and describesvarious exemplary embodiments. Various additions, modifications, andchanges may be made to the exemplary embodiments without departing fromthe spirit and scope of the disclosure. It is intended that all mattercontained in the above description or shown in the accompanying drawingsshall be interpreted as illustrative and not in a limiting sense.Additionally, the disclosure shows and describes only selectedembodiments of the disclosure, but the disclosure is capable of use invarious other combinations, modifications, and environments and iscapable of changes or modifications within the scope of the inventiveconcept as expressed herein, commensurate with the above teachings,and/or within the skill or knowledge of the relevant art. Furthermore,certain features and characteristics of each embodiment may beselectively interchanged and applied to other illustrated andnon-illustrated embodiments of the disclosure.

What is claimed is:
 1. An enclosure assembly of a hydraulic fracturingpower drive unit, the enclosure assembly comprising: an enclosure bodyat least partially defining an enclosure space to house the hydraulicfracturing power drive unit; one or more fan assemblies configured toflow air from an external environment surrounding the enclosure bodyalong an airflow path through the enclosure space; a radiator assemblyconfigured to receive a process fluid associated with the hydraulicfracturing power drive unit, the radiator assembly positioned adjacentthe airflow path such that the radiator assembly is configured to coolthe process fluid; a temperature sensor configured to detect atemperature of the enclosure space and output a temperature signal; anda controllers in electrical communication with the temperature sensor,the controller configured to activate at least one of the one or morefan assemblies responsive to the temperature signal, thereby to cool theprocess fluid and maintain a desired temperature of the enclosure space.2. The enclosure assembly of claim 1, wherein the one or more fansassemblies includes an intake fan assembly and an outtake fan assembly,wherein the enclosure body includes a plurality of side walls, andwherein the intake fan assembly is connected to a first side wall of theenclosure body and the outtake fan assembly is connected to a secondside wall of the enclosure body such that the airflow path extends fromthe intake fan assembly to the outtake fan assembly within the enclosurespace.
 3. The enclosure assembly of claim 2, wherein each of the intakefan assembly and the outtake fan assembly includes a hydraulic motor oran electric motor.
 4. The enclosure assembly of claim 1, furthercomprising a hydraulic heat exchanger assembly for cooling process fluidassociated with one or more hydraulic components in operativecommunication with the hydraulic fracturing power drive unit.
 5. Theenclosure assembly of claim 1, wherein the process fluid comprises oneor more of: (a) a lubrication fluid for absorbing heat from thehydraulic fracturing power drive unit, or (b) a hydraulic fluid forpressurizing one or more hydraulic components in operative communicationwith the hydraulic fracturing power drive unit.
 6. The enclosureassembly of claim 1, wherein the enclosure body comprises a plurality oflayers, and wherein at least one of the plurality of layers isconfigured to restrict sound transmission therethrough.
 7. The enclosureassembly of claim 6, wherein the plurality of layers includes: an innermetallic layer; an outer metallic layer; and a foam layer and a woollayer positioned between the inner metallic layer and the outer metalliclayer.
 8. The enclosure assembly of claim 1, wherein the temperaturesensor includes: (a) an analog sensor configured to produce an analogelectrical signal corresponding to the temperature of the enclosurespace, or (b) a digital sensor configured to produce a digitalelectrical signal corresponding to the temperature of the enclosurespace.
 9. A fluid pumping system for hydraulic fracturing operations,the fluid pumping system comprising: a power drive unit; a fluid pumpoperatively connected to the power drive unit; an enclosure assemblyincluding an enclosure body at least partially defining an enclosurespace to house the power drive unit; one or more fan assembliesconfigured to flow air from an external environment surrounding theenclosure body along an airflow path through the enclosure space; aradiator assembly configured to receive a process fluid associated withthe power drive unit, the radiator assembly positioned adjacent theairflow path such that the radiator assembly is configured to cool theprocess fluid; a temperature sensor configured to detect a temperatureof the enclosure space and configured to output a temperature signal;and a controllers in communication with the temperature sensor, thecontroller configured to activate at least one of the one or more fanassemblies responsive to the temperature signal, thereby to cool theprocess fluid and maintain a desired temperature of the enclosure space.10. The fluid pumping system of claim 9, wherein the one or more fansassemblies includes an intake fan assembly and an outtake fan assembly,wherein the enclosure body includes a plurality of side walls, andwherein the intake fan assembly is connected to a first side wall of theenclosure body and the outtake fan assembly is connected to a secondside wall of the enclosure body such that the airflow path extends fromthe intake fan assembly to the outtake fan assembly within the enclosurespace.
 11. The fluid pumping system of claim 10, wherein each of theintake fan assembly and the outtake fan assembly includes a hydraulicmotor or an electric motor.
 12. The fluid pumping system of claim 9,further comprising a hydraulic heat exchanger assembly for coolingprocess fluid associated with one or more hydraulic components of thefluid pumping system.
 13. The fluid pumping system of claim 9, whereinthe process fluid comprises one or more of: (a) a lubrication fluid forabsorbing heat from at least one of the power drive unit or the fluidpump, or (b) a hydraulic fluid for pressurizing one or more hydrauliccomponents in operative communication with at least one of the powerdrive unit or the fluid pump.
 14. The fluid pumping system of claim 9,wherein the enclosure body comprises a plurality of layers, and whereinat least one of the plurality of layers is configured to restrict soundtransmission therethrough.
 15. The fluid pumping system of claim 14,wherein the plurality of layers includes: (a) an inner metallic layer;(b) an outer metallic layer; and (c) a foam layer and a wool layerpositioned between the inner metallic layer and the outer metalliclayer.
 16. The fluid pumping system of claim 9, wherein the temperaturesensor includes: (a) an analog sensor configured to produce an analogelectrical signal corresponding to the temperature of the enclosurespace, or (b) a digital sensor configured to produce a digitalelectrical signal corresponding to the temperature of the enclosurespace.
 17. An enclosure assembly of a hydraulic fracturing power driveunit, the enclosure assembly comprising: an enclosure body at leastpartially defining an enclosure space to house the hydraulic fracturingpower drive unit; a heat exchanger assembly connected to the enclosurebody for cooling a process fluid associated with the hydraulicfracturing power drive unit; a temperature sensor configured to detect atemperature of the enclosure space and output a temperature signal; anda controller in communication with the temperature sensor, thecontrollers operatively connected to one or more of the heat exchangerassembly such that the controllers is configured to activate the heatexchanger assembly responsive to the temperature signal, thereby to coolthe process fluid and maintain a desired temperature of the enclosurespace.
 18. The enclosure assembly of claim 17, wherein the heatexchanger assembly includes: one or more fans configured to flow airalong an airflow path within the enclosure space; and a radiatorassembly configured to receive the process fluid, the radiator assemblypositioned adjacent the airflow path.
 19. The enclosure assembly ofclaim 18, wherein the one or more fans assemblies includes an intake fanassembly and an outtake fan assembly, wherein the enclosure bodyincludes a plurality of side walls, and wherein the intake fan assemblyis connected to a first side wall of the enclosure body and the outtakefan assembly is connected to a second side wall of the enclosure bodysuch that the airflow path extends from the intake fan assembly to theouttake fan assembly within the enclosure space.
 20. The enclosureassembly of claim 17, wherein the process fluid comprises one or moreof: (a) a lubrication fluid for absorbing heat from the hydraulicfracturing power drive unit, or (b) a hydraulic fluid for pressurizingone or more hydraulic components in operative communication with thehydraulic fracturing power drive unit.
 21. The enclosure assembly ofclaim 17, wherein the enclosure body includes a plurality of layers,wherein at least one of the plurality of layers is configured torestrict sound transmission therethrough.
 22. The enclosure assembly ofclaim 21, wherein the plurality of layers includes: (a) an innermetallic layer; (b) an outer metallic layer; and (c) a foam layer and awool layer positioned between the inner metallic layer and the outermetallic layer.